AE581 Project.docx - UNIVERSITY OF MICHIGAN DEARBORN...

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UNIVERSITY OF MICHIGAN DEARBORN AUTOMOTIVE SYSTEMS ENGINEERING MATERIAL SELECTION IN AUTO DESIGN AENG-581 Final report Term project: Research and selection of materials for the roof structure of a car Prepared by: Karthick Kadhapalli Natarajan (80431110)
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ABSTRACT This case study involves doing research on the materials and manufacturing processes used to produce the roof structure of a car. The car is to be produced in the year 2020. Using the appropriate methodologies the best possible material and manufacturing processes is to be selected so that it meets the proposed requirements for the roof structure of the car. INTRODUCTION In the first part of the project research on various materials used for the roof structure of the car is carried out. In this case study five different kinds of materials and different types of alloys of each material is considered. The following materials are considered for this case study, Steel (5 different alloys), Aluminum alloys (5 different alloys), Magnesium (5 different alloys), Carbon fiber reinforced plastics (2 different alloys) and Glass fiber reinforced plastics (2 different alloys). Material property charts are created to interpret different material properties. The second step of the analysis leads to finding out function, constraints, objectives and free variables of the roof panel and cross beams so that material index values can be calculated to Ranking of materials is done to find out the advantages of each materials it has over the other. Each material is discussed with the supporting information so that the appropriate material can be selected for the roof structure of the car. Then the suitable manufacturing processes that could be used to form the roof structure is discussed. ROOF STRUCTURE OF A CAR An automobile roof or a car top is a part of the automobile that is placed above the passenger compartment which protects the occupants of the vehicle from external environmental factors like sun, wind, rain etc. The roof structure includes the outer roof panel, outer cage and the cross beams. The highest priority in designing any roof for an automobile is its performance and weight reduction (i.e. lowering the center of gravity of the vehicle). Therefore the integration of structural components into the roof of an automobile body structure requires an in-depth consideration of different aspects. Some examples of roof structures of different car models are given below. Figure 1 Aluminum roof of the Maybach luxury car (reference: Maybach)
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Figure 2 Ranger Rover Evoque with an aluminum roof alloy: Anticorodal-600PX (reference: Land Rover) Figure 3 Structure of Mercedes SL Aluminum hard top (reference: Novelis) MATERIALS AND DIFFERENT TYPES OF ALLOYS CONSIDERED FOR THE ROOF STRUCTURE OF THE CAR The following materials and its corresponding alloys are analyzed in this case study STEEL (Alloy steel) AISI 1340 steel, annealed at 800 0 C AISI 4023 steel, normalized at 925 0 C AISI 4118 steel, normalized at 910 0 C AISI 4130 steel, water quenched at 855 0 C AISI 2300 steel (UNS G23300 ALUMINUM (6000 series) Aluminum
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  • Winter '14
  • Vivek D.Bishe
  • Tensile strength, Magnesium, Material Index

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